Method for making laminated foam articles

Abstract

The present invention provides a unique and rapid method of producing a laminated foam article having permanent, pliable, decorative embossed lines or patterns which produce a relief-like article such as an embossed seat cushion or the like. In one aspect, the present invention comprises the steps of coating the surface of a foam layer with an adhesive, placing a sheet or layer of cover material on the adhesive-coated foam layer surface, compressing the covered foam layer with a die having heated projection such that regions of the foam layer adjacent the hot die melt to form embossed lines which are permanent yet pliable. Since the embossed lines are actually collapsed, melted regions of the foam layer, thick, high density foam layers may be embossed using the present invention. In another aspect, a trilaminate structure is fabricated by additionally bonding a backing layer to the side of said foam layer opposite that to which said cover material is bonded. In one embodiment, the adhesive is cured during the embossing step by the heat from a heated platen and press.

What is claimed is: 
     
       1. A method for making a laminated foam article comprising the steps of: applying an adhesive to one surface of a compressible foam layer, said adhesive applied in a concentration of about 30 to 150 grams of adhesive per square meter;   directly contacting said adhesive-bearing surface of said foam layer with a layer of cover material selected from the group consisting of natural fabrics and synthetic fabrics to form a bilayer;   placing said bilayer on a platen;   contacting said cover material layer of said bilayer with at least one heated projection at a temperature from about 150° to about 250° C.;   producing relative movement of said platen and said heated projection to compress regions of said foam layer adjacent said heated projection;   melting and collapsing said compressed regions of said foam layer using the heat of said projections for a period from about 30 to about 90 seconds to form permanent embossed lines in said bilayer; and   removing said projections from said bilayer and solidifying said melted collapsed regions of said foam layer.   
     
     
       2. The method for making a laminated foam article recited in claim 1 wherein said foam layer includes polyurethane foam. 
     
     
       3. The method for making a laminated foam article recited in claim 1 wherein said foam layer includes polyether polyurethane foam. 
     
     
       4. The method for making a laminated foam article recited in claim 1 wherein said foam layer has a density of from approximately 14 kg/m 3  to 52 kg/m 3 . 
     
     
       5. The method for making a laminated foam article recited in claim 1 wherein said foam layer has a thickness of from approximately 1/8 inch to about 2 1/2 inches. 
     
     
       6. A method for fabricating a laminated foam article comprising: providing a layer of foam having two sides;   coating said sides of said foam layer with a heat curable adhesive, said adhesive applied in a concentration of about 30 to 150 grams of adhesive per square meter;   directly contacting one of said heat curable adhesive coated sides of said foam layer with a cover material selected from the group consisting of natural fabrics and synthetic fabrics to form a bilayer;   contacting the other heat curable adhesive coated side of said foam layer with a backing material to form a trilayer;   placing said trilayer on a platen with said backing material adjacent said platen;   providing a press having an attached die, said die having die projections at a temperature from about 150° C. to about 250° C.;   contacting said cover material of said trilayer with said die projections;   compressing said regions of said trilayer on said platen by causing relative movement of said die projections toward said platen;   conducting heat through said die projections to collapse areas of said foam layer in the region of said die projections for a period from about 30 to about 90 seconds to collapse and liquefy said regions of said foam layer;   heating said platen and said press;   curing said adhesive with said heat from said heated press and heated platen;   removing said die projections from said trilayer;   whereby said melted regions of said foam layer solidify forming embossed lines and whereby said cured adhesive bonds said cover material and said backing material to said foam layer.   
     
     
       7. The method for making a laminated foam article recited in claim 6 wherein said foam layer includes polyurethane foam. 
     
     
       8. The method for making a laminated foam article recited in claim 6 wherein said foam layer includes polyether polyurethane foam. 
     
     
       9. The method for making a laminated foam article recited in claim 6 wherein said foam layer has a density of from approximately 14 kg/m 3  to 52 kg/m 3 . 
     
     
       10. The method for making a laminated foam article recited in claim 6 wherein said foam layer has a thickness of from approximately 1/8 inch to about 21/2 inches. 
     
     
       11. A method for fabricating a laminated foam article comprising the steps of: coating one surface of a layer of foam with an adhesive, said adhesive applied in a concentration of about 30 to about 150 grams of adhesive per square meter;   placing a layer of cover material directly on said adhesive-coated surface of said foam layer, said cover material being selected from the group consisting of natural fabrics and synthetic fabrics;   curing said adhesive to bond said layer of cover material to said foam layer;   compressing regions of said foam layer with heated die projections at a temperature from about 150° C. to about 250° C. for a period from about 30 to about 90 seconds to melt said regions of said foam layer; and   solidifying said melted regions of said foam layer to form an embossed pattern.   
     
     
       12. A method for making a laminated foam article comprising the steps of: (a) providing a solvent-based adhesive;   (b) applying a coating of said solvent-based adhesive to one surface of a compressible foam layer, said adhesive applied in a concentration of about 30 to about 150 grams of adhesive per square meter;   (c) directly contacting said coated surface of said compressible foam layer with a cover material selected from the group consisting of natural fabrics and synthetic fabrics to form a bilayer;   (d) placing said bilayer on a platen;   (e) concentrating said cover material of said bilayer with at least one heated projection at a temperature from about 150° C. to about 250° C.,   (f) drying said solvent-based adhesive to bond said cover layer to said compressible foam layer;   (g) producing relative movement of said platen and said heated projection to compress regions of said foam layer adjacent said heated projection;   (h) melting and collapsing said compressed regions of said foam layer using the heat of said projections for a period from about 30 to about 90 seconds to form permanent embossed lines in said bilayer; and   (i) removing said projections from said bilayer and solidifying said melted collapsed regions of said foam layer; whereby said cover layer is securely bonded to said compressible foam layer and said bilayer is permanently embossed.     
     
     
       13. The method recited in claim 12, wherein said compressible foam layer is polyether polyurethane foam. 
     
     
       14. The method recited in claim 12, wherein step (f) is carried out during steps (c) through (i). 
     
     
       15. A method for fabricating a laminated foam article comprising: (a) providing a layer of foam having two sides;   (b) providing a heat curable, solvent-based adhesive;   (c) coating said sides of said foam layer with said adhesive, said adhesive applied in a concentration of about 30 to about 150 grams of adhesive per square meter;   (d) directly contacting one of said adhesive-coated sides of said foam layer with a cover material selected from the group consisting of natural fabrics and synthetic fabrics to form a bilayer;   (e) contacting the other adhesive-coated side of said foam layer with a backing material to form a trilayer;   (f) placing said trilayer on a platen with said backing material adjacent said platen;   (g) providing a press having an attached die, said die having die projections at a temperature from about 150° C. to about 250° C.;   (h) contacting said cover material of said trilayer with said die projections;   (i) compressing said regions of said trilayer on said platen by causing relative movement of said die projections toward said platen to produce compressed areas of said foam layer;   (j) conducting heat through said die projections for a period from about 30 to about 90 seconds to compressed areas of said foam layer in the region of said die projections to collapse and liquefy said compressed areas of said foam layer;   (k) heating said platen and said press;   (l) drying and curing said adhesive with said heat from said heated press and said heated platen;   (m) removing said die projections from said trilayer; whereby said melted regions of said foam layer solidify forming embossed lines and whereby said cured adhesive bonds said cover material and said backing material to said foam layer.     
     
     
       16. The method recited in claim 15, wherein said compressible foam layer is polyether polyurethane foam. 
     
     
       17. The method of claim 15, wherein step (l) is carried out during steps (d) through (m).